Brake disc and manufacturing method thereof

Abstract

A brake disc used for brake systems of motor vehicles, rail vehicles and aircrafts and the brake disc includes a brake disc body, wherein the brake disc body is an aluminum alloy brake disc body, the two working surfaces of the aluminum alloy brake disc body are respectively attached with a wear-resistant layer, the wear-resistant layers are wear-resistant layers made of ceramic high-temperature resistant metal matrix composite (MMC) reinforced materials, and the wear-resistant layers made of ceramic high-temperature resistant MMC reinforced materials metallurgically bond with the aluminum alloy brake disc body through a squeeze casting technique.

Description

BACKGROUNDTechnical Field[0001]The invention relates to a key part of brake systems of motor vehicles, rail vehicles, aircrafts and the like, in particular to a brake disc and a manufacturing method thereof.Description of Related Art[0002]Brake discs are important safety parts of motor vehicles, rail vehicles and aircrafts. Mechanical energy is converted into heat energy through friction between the brake discs and brake pads so as to stop the wheels from running, and therefore, reliable braking is of great importance. If braking fails in emergency circumstances, safety accidents can be caused, and even car crashes can be caused. For this reason, the brake discs are extremely important safety parts. At present, as the concept of energy conservation, environmental friendliness and lightweight has become the important development direction of motor vehicles, rail vehicles and aircrafts, lightweight of the brake discs is of more important significance. As the weight of the brake discs ...

AI Technical Summary

Benefits of technology

The invention is a brake disc made of lightweight aluminum alloy, which reduces the weight of motor vehicles, rail vehicles, and aircrafts by over 50%. The brake disc is reinforced selectively, has superior wear resistance and heat dissipation performance compared to traditional cast iron discs. It is made with high-temperature resistant materials, improves trafficability, reduces brake distance, and is suitable for automatic mass production. The brake disc is low in weight, high in strength, good in wear-resistance and heat-dissipation performance, long in service life, and cost-effective. It is about the same weight as carbon fiber ceramic discs and nodular cast iron discs in use cost.

Problems solved by technology

If braking fails in emergency circumstances, safety accidents can be caused, and even car crashes can be caused.

The carbon fiber ceramic discs obtained after carbon fiber materials are immersed in resin glue and then cured at a high temperature and are extremely expensive, thereby only being applied to aircrafts and a few of luxury vehicles.

Firstly, the density of nodular cast iron is high and reaches about 7.3 g / cm3, for example, the weight of one brake disc, with the diameter 355 mm, applied to a vehicle reaches about 11.78 Kg (equivalent to the sprung weight 35.34-58.9 Kg); as one vehicle needs four brake discs, the sprung weight of the vehicle is extremely high, oil consumption of the vehicle will be increased undoubtedly, and the maneuverability of the vehicle is reduced; and relevant component are difficult to assemble, disassemble and maintain.

Secondly, heat conductivity of cast iron is poor, frictional heat generated in the braking process is dissipated slowly, and consequentially, failures of brake systems are likely to be caused due to excessive temperature rise.

Thirdly, the cast iron brake discs are generally cast by sand casting, the dimensional accuracy and roughness of surface of the castings are poor, the shrinkage and porosity of the castings are difficult to control, energy consumption for casting is high, and pollution to the environment is severe.

Although the weight of the carbon fiber ceramic discs is only about half that of the nodular cast iron discs, the raw materials of the carbon fiber ceramic discs are expensive and the manufacturing device and technique for the carbon fiber ceramic discs are complex, and thus the price of the carbon fiber ceramic discs is over 50 times that of the nodular cast iron discs.

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